Projector unit



1951 R. K. BRAUNSDORFF 2,575,790

PROJECTOR UNIT Filed Dec. 30, 1949 6 INVENTOR.

REGINALD K. BRHUNSDORFF ZJQ M A T TORNE'Y Patented Nov. 20, 1951PROJECTOR UNIT Reginald K. Braunsdorff, East Orange,

to Tang-Sol Lamp Works, Inc.,

signor N. J as- Newark,

N. J a corporation of Delaware Application December 30, 1949, Serial No.135,967

6 Claims.

This invention relates to sealed electric lamp units and to themanufacture thereof.

One object of the invention is a sealed lamp unit comprising a reflectorelement and a baseless incandescent electric lamp bul A further objectof the invention is a lamp unit of theabove indicated character which isfurther characterized by the low cost of manufacture, by thesimplification of the electrical connections, by the high quality of theseal and by its rigidness and endurance.

Further objects of the after appear.

For a better understanding of the invention reference may be had to theaccompanying drawings wherein Fig. 1 is a schematic sectional view of asealed lamp unit embodying the invention;

Fig. 2 is a schematic view of another embodiment;

Fig. merit;

Fig. 3A is a schematic view of another embodiment; and

Fig. 4 is a schematic view of still another embodiment.

In one aspect the invention resides in a novel and improved lamp unitwherein the incandescent electric lamp bulb is directly fastened to thereinvention will herein- 3 is a schematic view of another embodiilectorelement and in a securely sealed manner 1 without the use of aconventional or standard base with the seal being of a character toprevent breathing.

Referring to the embodiment of Fig. 1, I have illustrated my inventionas embodied in a projector unit comprising a reflector I of any suitablecharacter as, for example, parabolic, or a combination of parabolic andother curvatures, and an electric incandescent lamp bulb 2. In thisembodiment of the invention the reflector I which may be made of anysuitable material, preferably metal, is formed with a centrally disposedinwardly extending tubular portion 3, terminating at any suitable pointwithin the reflector depend ing upon the shape, dimensions, etc. of thebulb 2. The lamp bulb 2 which in the particular embodiment shown is of aconventional bulbous shape having a reduced sealed-in part 2 is fastenedand sealed to the peripheral edge 3' of the reflector inward extension 3in any suitable manner. For this purpose the bulb 2 is solder treated inthe vicinity of the peripheral edge 3' of the reflector extension, thatis the bulb 2 is treated in any manner in this zone to enable thesoldering of the same to the metallic extension 3 of the reflector. Thistreatment of the bulb may consist of applying layers of metallic depositon which is applied a coating of tin (known as tinning), to which thesolder A is readily wetted.

The bulb having been treated, has applied thereto solder A and thesoldering operation is completed by the application of heat in anysuitable manner to the solder. The solder A is all the way around thebulb so as to form a tight seal at the peripheral edge 3 againstbreathing.

The focal point of the reflector is indicated at FC. In the manufactureof the bulb I can obtain a focal plane established at a distance, say of1 inch-1V, inch, an opening into which the glass bulb rests on aconventional sealing head for pull down, and also on the same diameterin the stamped reflector. This opening may be determined and establishedaccurately for both operations. A conventional sealing head pulldownpermits an accurate control of L. C. L. Axial alinement may be regulatedby tilting bulb in this opening. At the correct position heat may beapplied to the reflector as, for example, by induction or otherwise toallow the solder to soften and fasten the bulb to the metal reflector atthis point.

I have indicated a simple means for establishing electrical connectionwith the lamp unit. This comprises a disc 6 of any suitable material as,for example, fiber or plastic having a reduced tubular portion 5' on itsinner end which makes a press fit with or is otherwise fastened to theinward tubular extension 3. This button or block 6 carries suitableelectric terminals 1 and the lead-in wires 5 of the bulb 2 are solderedor otherwise fastened to these terminals.

In the embodiment of Fig. 2 the reflector I0 is indented at its rearcentral portion to form an integral outwardly extending tubular orcupshaped part II, the latter having a rounded peripheral edge H towhich the bulb 2 is fastened in a manner to obtain a secure seal againstbreathing. Treating of the bulb 2 and the soldering of the same to thereflector may be as described above with respect to Fig. 1.

In this embodiment I have shown one of the lead-in wires 5 turned aroundthe small end of the bulb and grounded to the reflector in the solder A.The other lead-in wire or weld 5 is electrically connected to a terminall2 of a terminal block I3, this terminal l2 passing through an openingin the end of the extension ll of the reflector and being provided onthe outside with a terminal Hi. The block I3 may be of any suitableinsulating material as, for example, flber or plastic.

In the embodiment of Fig. 3 I utilize a metallic sleeve I for theassembly of the lamp bulb 2 and the reflector I6. This sleeve method isapplicable to soldering the sleeve at its inner end to the lamp bulb ormay be converted for conventional basing with lamp cementing. Forinstance, the lamp bulb 2 may be fastened and sealed to the sleeve l5 atthe line I! by the soldering method as described in Fig. 2. Thisembodiment has a desirable focusing feature in that the sleeve I5 may beadjusted in or out in reference to the focal center of the parabolicreflector. Also with the end of the sleeve being open it permits aclinching or indenting operation for attaching to the reflector theindentations being indicated at l8. Any desired number of indentationsI8 may be provided for retaining the sleeve in the reflector butordinarily two or three such indentations are suflicient to accuratelylocate and fix the sleeve with reference to the reflector. Preferablythe sleeve is made of comparatively thin stock which would effect astill further saving in cost. Any suitable tools or machine may beemployed for performing this indenting operation as, for example, amachine resembling a conventional device used for crimping plasticbutton in basing. This may be made into a fully sealed lamp by merelypouring tar or other resinous material flush in the opening of thesleeve and about the edge of the tubular extension iii of the reflector.This is particularly suitable where the sleeve does not protrude beyondthe end 01' the extension 16'. This embodiment may be provided with anexternal connector as shown in Fig. l.

The embodiment of Fig. 3A is generally similar to the embodiment of Fig.3, the main difference being that instead of using the indentations 8 ofFig. 3 to fasten the reflector to the sleeve IS, in this embodiment Iutilize a crimped or fluted construction, these crimps or flutes beingformed in any suitable manner and being indicated generally at 20. Thisembodiment may be also provided with any suitable external connector as,for example, like that shown in Fig. 1.

In the embodiment of Fig. 4 the lamp bulb 2 is provided with a sleeve l5similar to the sleeve l5 of Figs. 3 and 3A. The reflector I and thesleeve l5 are firmly fastened together by rolling the edge of thereflector extension 25 and the edge of the sleeve together. The edge ofthe extension 25 is provided with an outwardly upturned flange 26. Anedge on the sleeve I5 is provided with an outwardly and upwardly rolledor turned portion 21 having a downwardly turned and interlocking flange21, the latter interlocking with the upwardly turned flange 26 of thereflector extension.

Any suitable external connector may be provided for the embodiment ofFig. 4 as, for example, either of the connectors illustrated in theembodiments described above.

Any suitable cover or lens is provided for the lamp units. In Fig. 1 Ihave illustrated schematically such a cover or lens indicated at 30.

I claim:

1. A sealed projector lamp unit comprising a reflector having a tubularextension formed symmetrically about the axis thereof, a baselessminiature incandescent lamp bulb hermetically sealed and firmly securedto said extension at the meeting area of said bulb and extension andexternal electrical connecting means for said unit having at least oneof the lead wires of the miniature bulb leading directly from the bulbto said electrical connecting means, said extension and bulb beingcoordinated to bring the bulb filament in the vicinity of the focalpoint of the reflector when the bulb is in contacting relationship withthe extension.

2. In a projector lamp unit of the character set forth in claim 1wherein the reflector tubular extension extends inwardly of thereflector with the neck of the bulb being soldered all the way aroundthe periphery thereof to the inner edge of said extension.

3. In a projector lamp unit of the character set forth in claim 1wherein the reflector tubular extension extends inwardly of thereflector with the neck of the bulb being soldered all the way aroundthe periphery thereof to the inner edge of said extension and theelectrical connecting means comprises an insulating plug supported inthe extension.

4. In a projector lamp unit of the character set forth in claim 1wherein the reflector tubular extension is formed outwardly of thereflector and the miniature bulb is sealed to the rounded shoulderformed between the reflector and the extension.

5. In a projector lamp unit of the character set forth in claim 1wherein the reflector tubular extension is formed outwardly of thereflector and the miniature bulb is sealed to the rounded shoulderformed between the reflector and the extension and the electricalconnecting means comprises an insulating plug carried within the outerend of the tubular extension.

6. A projector lamp unit comprising a reflector and a miniatureincandescent lamp bulb mounted directly on the reflector without theconventional base, with the bulb being fastened and sealed to thereflector against breathing by a single ring of sealing material and alens element for the unit.

REGINALD K. BRAUNSDORFF.

REFERENCES CITED The following references are of record in the flle ofthis patent:

UNITED STATES PATENTS Number Name Date 1,992,041 Roper et al. Feb. 19,1935 2,253,616 Falge Aug. 26, 1941 2,317,035 Dana Apr. 20, 19432,454,270 Braunsdorif Nov. 23, 1948

